Polymerization of olefins

ABSTRACT

A catalyst, a process of forming the catalyst, and polymerizing at least one alpha-olefin with the catalyst, said catalyst produced by precipitating a composition from a solution of a metal halide, for example, magnesium dihalide, and a transition metal compound, for example, titanium tetraalkoxide, in the presence of a particulate diluent, for example, polymeric fibrils, with an agent selected from among specified organometallic compounds, metal halides and oxygen-containing metal halides, hydrogen halides and organic acid halides. The composition is preferably further treated with a halide ion exchanging source, for example, titanium tetrahalide to form a particularly active catalyst. The catalyst is preferably used in combination with a cocatalyst comprising a metal hydride of organometallic compound selected from an element of Periodic Groups IA, IIA and IIIA.

BACKGROUND OF THE INVENTION

This is a divisional application of copending application Ser. No.380,788, filed May 21, 1982, now abandoned.

This invention relates to a process ior polymerizing olefins. In anotheraspect, this invention relates to a process for making a polymerizationcatalyst. In another aspect, this invention relates to a process forpolymerizing alpha-olefins using a catalyst system wherein the catalystis prepared by a novel process. In another aspect, this inventionrelates to a novel process for forming a catalyst which can be used witha cocatalyst to form a catalyst system for the polymerization ofalpha-olefins.

It is known to polymerize alpha-olefins and mixtures thereof at lowpressures with coordination catalysts. In this process, the catalystsused are prepared from mixtures of compounds of transition elements ofSubgroups IVB, VB, VIB of the Periodic Table and the organometalliccompounds of the elements of Groups I to III of the Periodic Table. ThePeriodic Table referred to herein is as shown on page B-2, 45th Edition(1964), of the Handbook of Chemistry and Physics, Chemical Rubber Co.The polymerization is generally carried out in suspension, in solutionor even in a gaseous phase.

Because of greater process economics, it is desirable to carry outolefin polymerization reactions, particularly polymerization reactionsinvolving ethylene and predominantly ethylene-containing copolymers, inan inert diluent at a temperature at which the resulting polymer doesnot go into solution, with the polymer being recovered without elaboratesteps to remove the catalyst. In order for this more economical methodof manufacture to be feasible from a practical standpoint the catalystmust be capable of producing polymer in high productivities in order tomaintain the residual catalyst level in the final polymer at a very lowlevel. The activity of an olefin polymerization catalyst is thus oneimportant factor in the continuous search for a catalyst useful for thepolymerization of alpha-olefins. It is also desirable that the processused in forming the catalyst be such as to allow ease in preparation andto allow control over the final catalyst formed.

In addition to catalyst productivity another important aspect of apolymerization process and catalyst is the properties of the polymerparticles produced. It is desirable to produce polymer particles whichare characterized by strength, uniformity of size, and a relatively lowamount of fines. Although polymer fluff having relatively highpercentages of fines can be handled with plant modifications, productionof a polymer in high productivity with low fines content is highlydesirable.

OBJECTS OF THE INVENTION

It is an object of this invention, therefore, to provide an improvedprocess for the polymerization of alpha-olefins.

Another object of this invention is to provide a novel and improvedmethod for preparing a catalyst composition.

A further object of this invention is to provide a novel catalystcomposition well adapted for the polymerization of alpha-olefins.

STATEMENT OF THE INVENTION

According to the invention, a polymerization catalyst is formed byprecipitation from a solution of a metal halide compound and atransition metal compound in the presence of a particulate diluent. Thecatalyst feeds easily into polymerization reactor and when used for thepolymerization of ethylene can produce a polyethylene product having alow content of fines. Thc catalyst can be made even more active bycontacting it with a source of halide ion to form an activated catalyst.The catalyst can be improved so that it will yield a more desirablepolymer product by forming a coating of prepolymer thereon, eitherbefore or after activation with halide. The activated composite can beemployed in combination with cocatalyst for the polymerization ofalpha-olefins, and is sufficiently active so that the content ofresidual catalyst in the polymer product can be maintained at adesirably low level.

DETAILED DESCRIPTION OF THE INVENTION

The catalyst of the present invention comprises a composition of matterresulting from the chemical combination of a metal halide compound and atransition metal compound in the presence of a particulate diluentwherein the metal halide compound is selected from metal dihalides andmetal hydroxyhalides and the metal of the metal halide compound isselected from Group IIA and Group IIB metals of the Periodic Table andwherein the transition metal of the transition metal compound isselected from Group IVB and Group VB transition metals of the PeriodicTable and the transition metal is bonded to at least one atom selectedfrom oxygen, nitrogen and sulfur, the oxygen, nitrogen and sulfur atomsbeing in turn bonded to a carbon atom of a carbon containing radical.

The metal halide compound is preferably selected from metal dihalidecompounds and metal hydroxyhalide compounds and the metal of the metalhalide compound is preferably selected from Group IIA and Group IIBmetals, such as for example beryllium, magnesium, calcium and zinc. Somesuitable metal halide compounds include for example, berylliumdichloride, beryllium dibromide, beryllium hydroxyiodide, magnesiumdichloride, magnesium dibromide, magnesium hydroxychloride, magnesiumdiiodide, magnesium difluoride, calcium dichloride, calcium dibromide,calcium hydroxybromide, zinc dichloride, zinc difluoride, and zinchydroxychloride. While metal hydroxyhalide compounds are known in theart, they are not as common and as readily available as metal dihalidecompounds; therefore, metal dihalides are preferred. Of the metaldihalides, magnesium dihalides, and particularly magnesium dichloride ispreferred because it is readily available and relatively inexpensive andhas provided excellent results. The metal dihalide component isgenerally used in the form of a substantially anhydrous, particulatesolid to facilitate its reaction with the transition metal compound. Itis also noted that various techniques for converting a metal halidecompound to a fine particulate form, such as for example roll milling,reprecipitating, etc., can be used to prepare the metal halide compoundfor use according to the present invention and that such additionalpreparation of the metal halide compound promotes the reaction of themetal halide compound with the transition metal compound; however, itdoes not appear to make any difference in a catalyst of the presentinvention whether the metal halide compound is in a fine particulateform. That is, polymer productivity, for example, is not a function ofthe size of the particles of the metal halide compound. Preparation ofmetal hydroxyhalide compounds are described in K. Soga, S. Katano, Y.Akimoto and T. Kagiya, "Polymerization of alpha-Olefins with SupportedZiegler-type Catalysts", Polymer Journal, Vol. 2, No. 5, pp. 128-134(1973).

The transition metal of the transition metal compound noted above ispreferably selected from Group IVB and Group VB transition metals and isgenerally selected from titanium, zirconium, and vanadium although othertransition metals can be employed. The transition metal derivatives mostadvantageously used in preparing the first catalyst component arepreferably described by the formula M(OR)_(a) X_(b-a) in which Mrepresents a transition metal, b is the valence of M, a is an integerbetween 0 and 4, and R represents a hydrocarbyl radical having fromabout 1 to about 20 carbon atoms. For example, R can be selected fromamong alkyl, cycloalkyl, and aryl groups and combinations thereof suchas alkaryl. X represents a halogen atom, for example bromine, chlorine,or iodide, more usually bromine or chlorine. Preferably, M representstitanium, zirconium, and vanadium, more preferably titanium. Exemplarycompounds include titanium tetramethoxide, titanium tetraeicosyloxide,titanium tetracyclohexyloxide, titanium tetrabenzyloxide, titaniumtrimethoxide-n-butoxide, titanium ethoxytrichloride, titaniumdibutoxidedioctadecyloxide, titanium diisopropoxydibromide, titaniumphenoxytrichloride, titanium tri-xylenyloxychloride, titaniumtetrabromide, titanium tetrachloride and titanium tetraiodide. Atitanium alkoxide, represented by the formula Ti(OR')₄, wherein R'represents an alkyl radical having from about 2 to to about 8 carbonatoms, for example, titanium tetra-n-butoxide, is presently preferred.

Other transition metal compounds which can be usefully employed includefor example titanium tetracetate, zirconium tetrahydrocarbyloxides,zirconium tetraimides, zirconium tetraamides, zirconiumtetramercaptides, vanadium tetrahydrocarbyloxides, vanadium tetraimides,vanadium tetraamides and vanadium tetramercaptides.

The molar ratio of the transition metal compound to the metal halidecompound can be selected over a relatively broad range. Generally themolar ratio is within the range of about 10:1 to about 1:10, preferablybetween about 3:1 and 0.5:2, however, the most common molar ratios arewithin the range of about 2:1 to about 1:2. When titaniumtetrahydrocarbyloxide and magnesium dichloride are employed to form thecatalyst, a molar ratio of titanium to magnesium of about 2:1 ispresently recommended as particularly active catalysts are derivedtherefrom.

The metal halide compound and the transition metal compound employed inthe present invention are normally mixed together during heating. Forexample, the two components can be refluxed together in a suitable drysolvent or diluent, which is inert to these components and the productproduced. Although reference is made throughout the specification to asolution of metal halide and transition metal compound, it is to beunderstood that the solution may not contain the compounds Per se, butrather, may contain a complex or the like. By the term "inert" is meantthat the solvent does not chemically react with the dissolved componentssuch as to interfere with the formation of the product or the stabilityof the product once it is formed. Such solvents or diluents include, forexample, n-pentane, n-hexane, n-heptane, methylcyclohexane, toluene,xylenes and the like. Aromatic solvents such as for example xylene, maybe desirable in some instances because the solubility of some metalhalide compounds and some transition metal compounds is higher inaromatic solvents as compared to aliphatic solvents. This can bedetermined easily by the ordinary artisan.

Generally the amount of solvent or diluent employed can be selected overa broad range. Usually the amount of solvent or diluent is within therange of about 1, more preferably about 20, to about 100 cc per gram ofmetal dihalide. The temperature employed during the heating step canalso be selected over a broad range. Normally the heating temperature iswithin the range of about 15° C. to about 150° C. when the heating stepis carried out at atmospheric pressure. Obviously the heatingtemperatures employed can be higher if the pressure employed is aboveatmospheric pressure. The pressure employed during the heating step doesnot appear to be a significant parameter. The heating step insures rapiddissolution of solid metal halides. In addition to the above notedsolvents or diluents, more polar solvents or diluents such asnitrobenzene and halogenated hydrocarbons, e.g methylene chloride,chlorobenzene and 1,2-dichloroethane can be used, particularly whenproducing compositions of the invention having a molar ratio of thetransition metal compound to the metal dihalide compound of other than2:1. In addition, normal saturated alkanols, such as, for example,ethanol, n-butanol and the like, and saturated ethers particularlysaturated cyclic ethers such as, for example, tetrahydrofuran, can beused alone or in combination with the previously mentioned solvents ordiluents. Mixed solvents or diluents, such as for example, a mixture ofn-hexane and tetrahydrofuran having a volume/volume ratio of, forexample, about 50/50 can be employed in solubilizing metal dihalideswhich are relatively difficult to solubilize, such as, for example, zincdichloride and the like. Other suitable mixtures of two or more of theabove solvents to solubilize the reagents combined to form the catalystcan of course also be used and can be readily determined by one ofordinary skill in the art.

Generally, the time required for heating these two components togetheris within the range of about 5 minutes to about 10 hours, although inmost instances a time within the range of about 15 minutes to about 3hours is sufficient.

The metal halide compound and transition metal compound are preferablyprecipitated in the presence of the particulate diluent by use of asuitable precipitating agent. Preferably, the precipitating agent isselected from the group consisting of organometallic compounds in whichthe metal is selected from metals of Groups I to III of the PeriodicTable, metal halides and oxygen-containing halides of elements selectedfrom Groups IIIA, IVA, IVB, VA, and VB of the Periodic Table, hydrogenhalides, and organic acid halides expressed as ##STR1## wherein R" is analkyl, aryl, cycloalkyl group or combinations thereof containing from 1to about 12 carbon atoms and X is a halogen atom. Mixtures of thesematerials can also be used.

Some organometallics in which the metal is selected from metals of GroupI, Group II, and Group III of the Periodic Table suitable ior use as theprecipitating agent include, for example, lithium alkyls, Grignardreagents, dialkyl magnesium compounds, dialkyl zinc compounds,organoaluminum compounds, etc. The organoaluminum compound is generallyan organoaluminum halide compound which includes for example,dihydrocarbylaluminum monohalides of the formula R'"₂ AlX,monohydrocarbylaluminum dihalides of the formula R'"AlX₂ and aluminumcompounds represented by the formula R'"₃ Al₂ X₃ wherein each R'" in theabove formulas is individually selected from aryl and linear andbranched chain hydrocarbyl radicals containing from 1 to about 20 carbonatoms per radical and can be the same or different and each X is ahalogen atom and can be the same or different. Some suitableorganoaluminum halide compounds include, for example, methylaluminumdibromide, ethylaluminum dichloride, ethylaluminum diiodide,isobutylaluminum dichloride, dodecylaluminum dibromide, dimethylaluminumbromide, diethylaluminum chloride, diisopropylaluminum chloride,methyl-n-propylaluminum bromide, di-n-octylaluminum bromide,diphenylaluminum chloride, diisopropylaluminum chloride, methylaluminumsesquibromide, ethylaluminum sesquichloride, ethylaluminum sesquiiodide,and the like. Ethylaluminum sesquichloride and ethylaluminum dichloride,have been employed with good results and are preferred.

Some metal halides and oxygen-containing halides of elements selectedfrom Groups IIIA, IVA, IVB, VA, and VB suitable for use as theprecipitating agent preferably include such as, for example, aluminumtribromide, aluminum trichloride, aluminum triiodide, tin tetrabromide,tin tetrachloride, silicon tetrabromide, silicon tetrachloride,phosphorus oxychloride, phosphorus trichloride, phosphorus pentabromide,vanadium tetrachloride, vanadium oxytrichloride, vanadyl trichloride,zirconium tetrachloride, and the like.

The hydrogen halides suitable for use as the precipitating agent includepreferably such as, for example, hydrogen chloride, hydrogen bromide,and the like.

The organic acid halides suitable for use as the precipitating agentpreferably include such as, for example, acetyl chloride, propionylfluoride, dodecanoyl chloride, 3-cyclopentylpropionyl chloride,2-naphthoyl chloride, benzoyl bromide, benzoyl chloride, and the like.

The molar ratio of the transition metal compound to the precipitatingagent can be selected over a relatively broad range. Generally, themolar ratio of the transition metal to the precipitating agent is withina range of from about 10:1 to about 1:10, more generally within a rangeof about 2:1 to about 1:3, still more preferably between about 2:1 to1:1 since a molar ratio within the latter range usually produces acatalyst which can be employed as an especially active ethylenepolymerization catalyst.

The particulate diluent in the presence of which the metal halidecompound and transition metal compound are precipitated can be selectedfrom a wide range of materials, for example, silica, silica-alumina,silica-titania, magnesium dichloride and magnesium oxide are suitable,as well as polymeric materials, such as poly(phenylene sulfide).Polyolefins, for example polyethylene or polypropylene, are preferredparticulate diluent, because they are generally compatible withpolymeric polyolefin product. Polyolefins in fibrous form, such aspolyethylene fibrils are preferred, because they have been used withgood results.

The polyolefin fibrils can be prepared by diluting a hot solution of thepolymer with relatively cool solvent while simultaneously subjecting themixture to shearing forces imparted by mixing blades such as in a WaringBlender or the like. (See, for example, U.S. Pat. No. 4,013,751, Example1.)

The resulting fibrils generally have lengths on the order of about 1 to15 mm and diameters on the order of about 0.005 to 0.1 mm. (Thedimensions of the invention fibrils were not determined, so the abovefigures are based on the above reference as well as U.S. Pat. No.4,237,081, line, line 53.) Preferably, the metal halide compound andparticulate diluent are thoroughly admixed, such as by being milledtogether, prior to their introduction into the solvent for the metalhalide.

Generally, the particulate diluent portion of the catalyst in thisembodiment of the invention will comprise from about 5 to about about 75percent based on total weight of the composition. The total weight ofthe composition as used here means the combined weights of precipitateand particulate diluent. Usually, about 20 to about 75 weight percent ofthe material will be diluent. Preferably, about 30 to about 50 weightpercent of the material will be particulate diluent. The concentrationof the metallic components catalyst can vary over a wide range.

Prepolymer can be polymerized onto the catalyst described above to forman improved catalyst. This material can be recovered and used inpolymerization processes to produce polymer product having a moredesirable particle size. It can be desirable to treat this type ofcatalyst with conventional ethylene anti-static agents to aid inhandling and metering.

The prepolymerization step can comprise, as indicated above,prepolymerizing a minor but effective amount of aliphatic alpha-olefinonto the catalyst produced by precipitation from the solution of metalhalide compound and transition metal compound in the presence ofparticulate diluent.

The prepolymerizing step can be performed by any method effective forprepolymerizing polymer onto the catalyst. For example, theprecipitating step can be entirely carried out under an olefinatmosphere; or the precipitating step can be carried out by adding aportion of the precipitating agent under a dry inert atmosphere followedby adding another portion of the precipitating agent under an olefinatmosphere; or other variations can be employed by one skilled in theart in accordance with the invention. Preferably, the prepolymerizingstep is carried out by adding an olefin for example, ethylene, to thecatalyst and recovering the improved catalyst which contains polymerdeposited thereon, preferably with washing. Improved catalysts preparedin this manner produce low fines content polymer product when used inpolymerization processes.

The monomer which is utilized for prepolymerization can be the same asor different from the monomer used in the polymerization process as setout hereinafter. Preferably the same monomer is used. The aliphaticmono-1-olefins can preferably have between 2 and 10 carbon atoms permolecule and broadly between 2 and about 18 carbon atoms per molecule.Prepolymerization can also use conjugated diolefins, preferably such asthose having from 4 to 8 carbon atoms per molecule. Most preferablyethylene is used for prepolymerization, since its properties will besimilar to those of the product when the catalyst is employed forethylene polymerization.

The weight of prepolymer is based on the total weight of thecomposition, as indicated above, and is generally from about 1 to about50% by weight of the total composition, preferably from about 3% toabout 40% by weight, and more preferably from about 5% to about 20% byweight of the total composition since this is believed to result in acatalyst with good feeding characteristics that can produce a polymerhaving relatively low fines content. The total weight of the compositionhere refers to the combined weights of precipitate, particulate diluentand prepolymer.

The catalyst is preferably treated with a halide ion exchanging source,preferably a halogenated transition metal compound to form an activatedcatalyst. The treatment can be conducted before or afterprepolymerization, preferably after, and is carried out by contactingthe catalyst with the halogenated transition metal compound at atemperature sufficient to provide a reaction. Suitable preferredcompounds can be represented by the formula M in which M'X_(c)(OR)_(d-c) in which M' is selected from the group consisting ofzirconium, titanium, vanadium, silicon and tin, d is the valence of M',X stands for bromine, chlorine or iodine or mixtures thereof, c is lessthan d and is an integer of 1 to 4 and R is an alkyl, cycloalkyl or arylgroup and combination thereof, such as alkaryl, containing from 1 toabout 20 carbon atoms. More preferably, c equals d and is 2, 3 or 4.Most preferably M comprises titanium and c is 4. Specific examples ofsuitable compounds include titanium tetrachloride, titaniumdibromodichloride, titanium iodotrichloride, n-butoxytrichlorotitanium,chlorotridodecycloxytitanium, bromotricyclohexyloxytitanium,diphenoxydichlorotitanium, silicon tetrachloride, zirconiumtetrachloride, tin tetrachloride and the like. A presently preferredcompound comprises a titanium tetrahalide represented by the formualTiX₄ wherein X represents a halogen atom, for example, chlorine orbromine. Titanium tetrachloride is presently preferred because ofavailability and relatively low cost.

While it may not be necessary in all instances to employ a cocatalystwith the catalyst of the present invention, the use of cocatalyst isrecommended for good results. Preferably then the catalyst afterprepolymerization and halide in activation treatment is combined with acocatalyst, to form a highly active catalyst system useful for thepolymerization of olefins. The cocatalyst preferably comprises a metalhydride or an organometallic compound wherein the metal is preferablyselected from an element of Groups IA, IIA and IIIA of the PeriodicTable. In other words, the cocatalyst can be a hydride of the metals ofGroups IA, IIA, and IIIA or an organic compound of the metals.

The cocatalytic component of the catalyst system is preferably anorganoaluminum compound of the formula AlR_(e) Y_(3-e) where Rrepresents a hydrocarbyl radical containing from 1 to about 20 carbonatoms, Y represents a monovalent radical selected from the groupconsisting of hydrogen and halogen, and e is an integer of 1 to 3.Exemplary compounds include trihydrocarbyl aluminum compounds such astrimethylaluminum, triethylalauminum, tridodecylaluminum,trieicosylaluminum, triphenylaluminum, dihydrocarbylaluminum halidessuch as diethylaluminum chloride, dibutylaluminum bromide;hydrocarbylaluminum dihalides such as methylaluminum dichloride,isopropylaluminum dibromide; and mixtures such as hydrocarbylaluminumsesquihalides such as ethylaluminum sequichloride. Presently preferredare trialkylauminum compounds, represented by the formula AlR"'₃ whereinR'" represents an alkyl radical having from about 2 to about 8 carbonatoms.

It is within the scope of this invention to employ one or moreadjuvants, these being polar organic compounds, i.e., Lewis bases(electron donor compounds) with the titanium tetrahalide component orthe cocatalyst component or both. Suitable compounds for this purposeare described in U.S. Pat. No. 3,642,746, the disclosure of which isincorporated by reference. They include alcoholates, aldehydes, amides,amines, arsines, esters, ethers, ketones, nitriles, phosphines,phosphites, phosphoramides, sulfones, sulfoxides and stibines. Exemplarycompounds include sodium ethoxide, benzaldehyde, acetamide,triethylamine, trioctyl arsine, ethyl acetate, diethyl ether, acetone,benzonitrile, triphenyl phosphine, triphenyl phosphite, hexamethylphosphoric triamide, dimethyl sulfone, dibutyl sulfoxide, triethylstibine and dimethyl aniline.

Preferred esters are the lower alkyl esters (1 to 4 carbon atoms permolecule) of benzoic acid which may be additionally substituted in thepara position to the carboxyl group with a monovalent radical selectedfrom the group consisting of --F, --Cl, --Br, --I, --CH₃, --OR"',--OOCR"', --SH, --NH₂, --NR"'₂, --NHCOR"', --NO₂, --CN, --CHO, --COR"',--COOR"'. --C₂ NH₂, --CONR"'₂, --SO₂ R"', and --CF₃. Exemplary compoundsinclude ethyl anisate (ethyl p-methoxybenzoate), methyl para-toluate,methyl benzoate, ethyl benzoate, ethyl p-dimethylaminobenzoate, ethylp-trifluoromethylbenzoate, methyl p-hydroxybenzoate, methylp-acetylbenzoate, methyl p-nitrobenzoate, ethyl p-mercaptobenzoate andmixtures thereof. Particularly preferred compounds are ethyl anisate,ethyl benzoate and methyl para-toluate. Generally if an adjuvant is usedat all, it is used in the polymerization of propylene. In the preferredembodiments of this invention where ethylene is polymerized, an adjuvantis generally not used.

The molar ratio of organolauminum compound(s) to adjuvant(s) whenemployed is generally in the range of about 1:1 to about 300:1. Themolar ratio of titanium compound to adjuvant(s) when employed isgenerally in the range of about 1:1 to about 200:1. The atom ratio ofaluminum to titanium can range from about 20:1 to about 10,000:1 morepreferably from about 75:1 to about 5,000:1. The atom ratio of aluminumto magnesium can range from about 0.1:1 to about 4:1, more preferablyfrom about 0.5:1 to about 2:1.

Any alpha-olefin, or mixture thereof, can be polymerized in the presenceof the catalyst of the present invention with the preferred reactantbeing ethylene or ethylene plus another higher aliphatic mono-1-olefincontaining from 3-10 carbon atoms. The catalysts are of particularutility in the polymerization of ethylene or the copolymerization ofethylene and minor amounts of propylene, butene-1 or hexene-1, in aninert hydrocarbon diluent at a temperature at which the resultingpolymer is insoluble in the diluent.

By minor amounts is meant up to about a total of 20 mole % comonomer(s).

Broadly, the polymerization conditions employed in this invention aresimilar to certain known processes in which a catalyst system comprisinga titanium tetrahalide and an organoaluminum compound are used. Thealpha olefin is polymerized by contact with the catalyst system of thisinvention in solution, in suspension or in gaseous phase.

In the preferred process, ethylene is polymerized in a particle formsystem which is conducted in the presence of a diluent under conditionsof temperature and pressure such that the diluent is in the liquid phaseand the resulting polymer is insoluble in the diluent. Thepolymerization temperature generally falls in the range of 0° to 150°C., more preferably about 40° to 112° C. Any convenient partial pressureof ethylene can be used. The partial pressure generally falls within therange of about 10 to 500 psia (69 to 3450 kPa). The concentration oftitanium compound per liter of diluent during the polymerization canvary within the range of about 0.0005 to 10, more preferably from about0.001 to 2 millimoles per liter of diluent.

The diluent used in the polymerization process is one which isunreactive under the conditions employed, although in certain instances,the diluent and monomer can be the same. The diluent is preferably ahydrocarbon such as isobutane, n-pentane, cyclohexane and the like.

As is known in the art, control of the molecular weight of the polymercan be obtained by the presence of hydrogen in the reactor duringpolymerization.

The polymerization process used for producing ethylene polymers,according to this invention, can be any of the well-known processesincluding batch and continuous processes.

It is convenient when polymerizing ethylene in bench scale process, forexample, to conduct the polymerization batchwise in a stirred reactoremploying a dry hydrocarbon diluent inert in the process such asisobutane, n-heptane, methylcyclohexane, benzene, toluene, and the likeat a reactor temperature of about 100° C. and a reactor pressure ofabout 500-650 psia (3.4-4.5 MPa). Ethylene is admitted to the reactor asrequired to maintain the desired pressure. Molecular weight controlagents such as hydrogen can be employed in the reactor as known in theart to adjust the molecular weight of the polymer.

When the selected polymerization time is reached the reaction can beterminated by discontinuing the flow of ethylene and comonomer, if used,venting unreacted monomer(s) and diluent and recovering the polymer. Therecovered product can be treated to deactivate or remove catalystresidues such as by an alcohol wash, can be stabilized by admixture withan antioxidant(s) and can be dried to remove residual solvent, ifpresent and as is known in the art. The final product can be furtherprocessed into pellets and/or converted into the final shaped product.

In a continuous process, a suitable reactor such as a loop reactor iscontinuously charged with suitable quantities of solvent or diluent,catalyst, cocatalyst, ethylene, hydrogen (if any), and comonomer (ifany). Reactor product is continuously withdrawn and solid polymerrecovered from it by suitable means such as by flashing.

It is also emphasized that the compositions of matter of the presentinvention should be prepared in an oxygen free system e.g., absence ofair as well as a dry system i.e., absence of water. Generally a dry boxis employed as known in the art to prepare the compositions of thepresent invention usually employing a dry, oxygen-free nitrogen or argonatmosphere.

EXAMPLE 1 (Control) Prepolymer Applied to Catalyst

A catalyst was prepared in a 30 gal (113L) Pfaudler reactor by chargingit with 15 gal (56.7 L) of dry n-hexane, 1.23 lbs (5.88 moles) of dryMgCl₂ powder and 6 lbs (11.9 moles) of titanium tetraethoxide (Ti(OEt)₄)under a nitrogen atmosphere with stirring. The stirred mixture washeated to about 90° C., held there for 5 minutes and cooled to 25° C. Tothe mixture over a 4 hour period with cooling was added 12.5 lbs ofethylaluminum sesquichloride solution (EASC) as a 26 wt. percentsolution in n-heptane equivalent to 3.25 lbs (5.96 moles) of EASC. Thetemperature ranged from about 16° to 25° C. during the addition.Following the EASC addition, 1.2 lbs (544.3 g) of ethylene was chargedto the mixture over a 30 minute period of time with a reactortemperature of about 19° C. After stirring the mixture for about 20minutes longer the stirrer was turned off and the solids allowed tosettle. The mother liquor was decanted and catalyst slurry was washed(mixed) with about 6 gal (22 L) of fresh n-hexane, the slurry allowed tosettle and the wash liquid removed by decanting. The wash sequence wasrepeated 3 times using about 6 gal of fresh n-hexane each time with thetemperature ranging from about 19° to 23° C. After the final decanting10 gal (38 L) of n-hexane and 12 lbs (5.44 kg, 28.7 moles) of TiCl₄ wascharged. While stirring the mixture was heated to about 55° C. thencooled to about 31° C. The stirrer was turned off, the solids allowed tosettle and solids washed 4 times as before following thesolvent-decanting sequence previously used. The catalyst slurry wastransferred to a holding vessel pending further use. The calculatedamount of prepolymer was about 14 weight percent.

Individual portions of the dry catalyst were used in several runs forpolymerizing ethylene at 100° C. in a 1 gal (3.8 L) stirred stainlesssteel reactor containing 1200 mL (668 g) of dry isobutane diluent, 0.5mL (0.45 mmole) of triethylaluminum (TEA) as cocatalyst as a 15 wt.percent solution in n-heptane and the desired amount of hydrogen toprovide the desired polymer melt index. The hydrogen partial pressure(Δp) was supplied from a standardized pressurized 2425 mL vessel.

Each polymerization run was terminated by venting the gaseous reactants.The recovered polymer was dried, weighed to ascertain the yield,stabilized with about 0.2 weight percent of a conventional antioxidantsystem, and its melt index (MI) determined in accordance with ASTM D1238 at 190° C. and a load of 2.16 kg.

About 100 g of the dry, stabilized polymer sample recovered from eachrun was ground for 2 minutes in a Waring Blender at high speed. Theparticle size distribution of the ground polymer was determined byplacing the ground sample on a set of sieves having mesh sizes of 30,50, 80, 100, 200 and pan (U.S. Sieve Sizes) and mechanically agitatingthe set for 15 minutes. The amount of powder remaining on the pan andeach sieve was determined by weighing. The purpose of grinding thepolymer is to artifically simulate the attrition polymer particlesappear to receive in a large scale reactor such as a loop reactor sinceparticles formed in such reactors are generally finer than those made inbench scale reactors. The grinding results may be helpful to some extentas a screening guide in selecting catalysts that may provide coarserpolymer particles in a commercial operation.

Fines content is reported as the weight percent of polymer particlessmaller than 100 mesh.

Calculated catalyst productivity is reported as kg polymer per gcatalyst per hour, abbreviated kg/g/hr.

The other pertinent reactor conditions and the results obtained arereported in Table 1.

                                      TABLE 1                                     __________________________________________________________________________    Ethylene Polymerization With Control Catalyst                                 No Polymer Fibrils Used in Catalyst Production                                              Pressures  Polymer    Calculated                                Run                                                                              Catalyst                                                                           Cocatalyst                                                                          Hydrogen                                                                            Reactor                                                                            Yield  Fines                                                                             Productivity                              No.                                                                              mg.  mmole ΔP, MPa                                                                       MPa  g   MI Wt. %                                                                             kg/g/hr                                   __________________________________________________________________________    1   7.7 0.45  0.345 3.76 543  0.96                                                                            25.2                                                                              70.5                                      2  11.0 0.45  0.552 4.03 735 11.2                                                                             47.7                                                                              66.8                                      3  10.2 0.45  0.827 4.31 307 12.1                                                                             68.5                                                                              30.1                                      4  10.9 0.45  1.03  4.59 712 45.5                                                                             75.8                                                                              65.3                                      __________________________________________________________________________

The data based on the grinding test show that polymer fines increase asthe polymer melt index increases.

EXAMPLE 2 (Invention)

The catalyst was prepared in the presence of 5 g of linear high densitypolyethylene (HDPE) fibrils slurried into about 400 mL of dry xylenecontained in a 1 liter flask arranged for nitrogen purging, magneticstirring and refluxing. The fibrils were made by dissolving the HDPE inabout 400 mL of xylene at 120° C., then pouring the hot solution intoabout 200 mL of xylene in a Waring blender operating at moderate speed.The stirred mixture was cooled to about 25° C. at ambient temperaturethen the stirrer operated at high speed for about 1 minute. The HDPE hada high load melt index of about 1 as determined in accordance with ASTMD 1238 at a temperature of 190° C. and a load of 21.6 kg.

To the fibril slurry at about 25° C. was added 2 g (0.021 mole) of MgCl₂powder (dried under nitrogen for several hours at 420° C.) and 8.4 mL(9.3 g, 0.041 mole) of titanium tetraethoxide, Ti(OEt)₄. The mixture wasthen heated to about 70°-80° C. and held there for 1.5 hours to effectdissolution of the metal compounds, then cooled to room temperature(about 25° C.). To the cooled mixture over a 45 minute interval wasadded 30 mL (5.8 g, 0.026 mole) of a 25.4 wt. percent solution ofethylaluminum sesquichloride (EASC) contained in n-heptane. Theresulting slurry was stirred an additional 30 minutes then the settledsolids were washed 4 times with about 700 mL portions of dry n-hexanewith decanting of the wash liquid. The slurry was then diluted to about500 mL with fresh n-hexane, 10 mL (17.3 g) of TiCl₄ was added and themixture was stirred at room temperature for 1 hour. After settling, thesolids were isolated, washed with n-hexane until essentially all visualevidence of TiCl₄ in the wash liquid was gone, e.g. the filtrate wascolorless, and the washed solids were dried under vacuum at roomtemperature to provide a powder. The powder contained about 50 weightpercent HDPE fibrils and 50 weight percent catalyst.

Individual portions of the dry catalyst were used in polymerizingethylene in several runs in a particle form process as set forth inExample 1.

The pertinent reactor conditions and the results obtained are presentedin Table 2.

                                      TABLE 2                                     __________________________________________________________________________    Ethylene Polymerization                                                       Catalyst Prepared With HDPE Fibrils, No Prepolymer on Catalyst                              Pressures  Polymer    Calculated                                Run                                                                              Catalyst                                                                           Cocatalyst                                                                          Hydrogen                                                                            Reactor                                                                            Yield  Fines                                                                             Productivity.sup.(a)                      No.                                                                              mg.  mmole ΔP, MPa                                                                       MPa  g   MI Wt. %                                                                             kg/g/hr                                   __________________________________________________________________________    1  52.0 2.7   0.207 3.59 304 0.52                                                                             12.4                                                                              5.85                                      2  43.5 2.7   0.414 3.65 322 14.                                                                              39.4                                                                              7.40                                      __________________________________________________________________________     .sup.(a) Since the catalyst composition contains 50 weight catalyst the       calculated productivity in terms of kg polymer per g catalyst per hour        becomes 11.7 kg/g cat/hr in run 3 and 14.8 kg polymer/g cat/hr in run 4. 

As with the control catalyst of Example 1 the results indicate thatpolymer fines increase as polymer melt index increases. However, atabout the same polymer melt index level, the inventive catalyst producesless polymer fines than are those obtained with the control catalyst ofExample 1 containing polyethylene deposited thereon during catalystmanufacture. For example at a polymer MI of 14, the invention catalystgave polymer fines of about 39 weight percent. At polymer MI's of 11.2and 12.1, the control catalyst gave polymer fines of about 48 and 68weight percent, respectively. At a polymer MI of 14, the controlcatalyst would be expected to give polymer fines between about 69 to 76weight percent.

At a MI less than about 1, the invention catalyst produced aboutone-half the fines of the control catalyst. On a productivity basisalone the invention catalyst appears to be less active than the controlcatalyst. This is partly due to the higher cocatalyst level used in theinvention catalyst runs. Data accumulated with Ti-Mg catalysts made inthe manner shown for the control catalyst oi Example 1 indicate that,with a TEA cocatalyst, as the TEA content decreases irom about 3 mmoles(invention runs) to 0.5 mmole (control runs) the productivity of thecatalyst approximately doubles. Even compensating for this difference incocatalyst level the invention catalyst is less active. Since thecatalysts were prepared under somewhat different conditions (inventionin bench scale control in pilot plant scale) there were probablydifferent poison levels encountered. The trends observed, however, arestill valid for each catalyst and point out that less polymer fines aremade with the invention catalyst.

EXAMPLE 3 (Invention)

The catalyst was prepared in the manner and with the same quantities ofreagents described in Example 2. However, after treating the solution ofMgCl₂ and Ti(OEt)₄ containing HDPE fibrils with EASC solution a smalladditional amount, 2 mL (0.0017 mole) of EASC solution was added andethylene gas was bubbled into the slurry for 2 hours. The settled solidswere washed with n-hexane, treated with TiCl₄ and washed again withn-hexane as previously detailed.

This catalyst differs from that of Example 2 in that an estimated 10-15weight percent prepolymer (polyethylene) was applied to the catalystparticles during its preparation.

As before individual portions of the catalyst were used in several runsto polymerize ethylene.

The pertinent reactor conditions and the results obtained are reportedin Table 3.

                                      TABLE 3                                     __________________________________________________________________________    Ethylene Polymerization                                                       Catalyst Prepared With HDPE Fibrils and Containing Prepolymer                               Pressures  Polymer    Calculated                                Run                                                                              Catalyst                                                                           Cocatalyst                                                                          Hydrogen                                                                            Reactor                                                                            Yield  Fines                                                                              Productivity                             No.                                                                              mg.  mmole ΔP, MPa                                                                       MPa  g   MI Wt. %                                                                             kg/g/hr                                   __________________________________________________________________________    1  57.1 2.7   0.207 3.59 315  0.47                                                                             4.5                                                                              5.52                                      2  62.7 2.7   0.414 3.65 275 10.6                                                                             14.9                                                                              4.39                                      __________________________________________________________________________

In comparing the results in Table 3 with those of Table 2 it is evidentthat polymer fines can be additionally reduced by approximately 50percent by applying a prepolymer (polyethylene) to the catalystparticles which have been prepared in the presence of HDPE fibrils.

EXAMPLE 4 (Control)

The catalyst was prepared in the general manner described in Example 1except that a n-hexane solution of 0.95 lbs (4.52 moles) of MgCl₂ and5.3 lbs (10.5 moles) of Ti(O Et)₄ was simultaneously introduced into thestirred reactor at 50° C. with 10 lbs of ethylaluminum dichloride (EADC)solution as a 25 weight percent solution in n-heptane equivalent to 2.5lbs (8.93 moles) of EADC. The settled solids were by decantation asbefore, then treated with 7 lbs (16.7 moles) of TiCl₄ at 50° C. for 1hour and finally washed as before, then a portion thereof dried underargon in a dry box.

A portion of the dry product, 45 g, was admixed with 405 g of HDPEpowder overnight on a roller mill in a container containing a stainlesssteel rod to aid in the mixing process. The composition contained 10weight percent catalyst and 90 weight percent HDPE.

A portion of the dry catalyst and the HDPE-diluted catalyst wereindividually tested in ethylene polymerization as before, identified asruns 1 and 2, respectively, in Table 4.

The pertinent reactor conditions and the results obtained are reportedin Table 4.

                                      TABLE 4                                     __________________________________________________________________________    Ethylene Polymerization                                                       Catalyst Prepared In Absence of HDPE Fibrils But Diluted with HDPE                          Pressures  Polymer    Calculated                                Run                                                                              Catalyst                                                                           Cocatalyst                                                                          Hydrogen                                                                            Reactor                                                                            Yield  Fines                                                                             Productivity                              No.                                                                              mg.  mmole ΔP, MPa                                                                       MPa  g   MI Wt. %                                                                             kg/g/hr                                   __________________________________________________________________________    1   4.3 0.45  0.345 3.76 229 1.23                                                                              7.3                                                                              53.3                                      2  30.1 0.45  0.345 3.76 318 0.85                                                                             14.0                                                                               10.5*                                    __________________________________________________________________________     *On the basis of catalyst only since the diluted catalyst composition is      10 weight percent catalyst and 90 weight percent HDPE fines, the              calculated productivity then becomes 105 by polymer per g catalyst per        hour.                                                                    

The results in Table 4 indicate that diluting the catalyst with HDPEfines (powder) resulted in approximately doubling the amount of polymerfines in the grinding test compared to the undiluted catalyst at aboutthe same polymer melt index. This behavior is opposite to that observedwith the invention catalyst.

What is claimed is:
 1. A process comprising contacting at least onealpha-olefin with a polymerization catalyst under polymerizationconditions, wherein the polymerization catalyst comprises a particulatediluent and a product precipitated in the presence of the particulatediluent, the product being formed by mixing under precipitationconditions a component solution and a precipitating agent,wherein thecomponent solution is formed by the combination of: (1) a metal halidecompound selected from the group consisting of metal dihalide compoundsand metal hydroxyhalide compounds and the metal of the metal halidecompound is selected from the group consisting of Group IIA metals andGroup IIB metals of the Periodic Table, and (2) a transition metalcompound in which the transition metal is selected from the groupconsisting of Group IVB and Group VB transition metals of the PeriodicTable and the transition metal is bonded to at least one atom selectedfrom the group consisting of oxygen, nitrogen and sulfur, and saidoxygen, nitrogen and sulfur atoms are in turn bonded to a carbon atom ofa carbon containing radical, in a suitable solvent; wherein theprecipitating agent is selected from the group consisting oforganometallic compounds wherein the metal is selected from the groupconsisting of Group I, Group II, and Group III metals of the PeriodicTable, metal halides and oxygen containing halides of elements selectedfrom the group consisting of Group IIIA, Group IVA, Group IVB, Group VA,and Group VB of the Periodic Table, hydrogen halides, and organic acidhalides selected from the group consisting of compounds having theformula ##STR2## wherein R" is an alkyl, aryl, or cycloalkyl group orcombinations thereof containing from 1 to about 12 carbon atoms and X isa halide.
 2. A process as in claim 1 wherein the at least onealpha-olefin comprises a mono-1-olefin.
 3. A process as in claim 1wherein the at least one alpha-olefin comprises ethylene.
 4. A processas in claim 1 wherein the catalyst further comprises an amount ofprepolymer deposited on the catalyst.
 5. A process as in claim 4 whereinthe particulate diluent comprises polyethylene fibrils and wherein theprepolymer comprises polyethylene.
 6. A process as in claim 4 whereinthe particulate diluent comprises silica.
 7. A process as in claim 6wherein the catalyst further comprises in combination at least oneorganoaluminum compound represented by the formula AlR"'_(e) Y_(3-e)wherein R"' represents a hydrocarbyl radical containing from 1 to about20 carbon atoms, Y represents a monovalent radical selected from thegroup consisting of hydrogen and halogen and e is an integer of 1 to 3,the combination forming a catalyst system.
 8. A process as in claim 7wherein the catalyst system is contacted with ethylene in a presence ofa liquid hydrocarhon diluent under conditions of temperature andpressure such that the diluent is in the liquid phase and the resultingpolymer is substantially insoluble in said diluent.
 9. A processcomprising contacting at least one alpha-olefin with a polymerizationcatalyst together with a suitable cocatalyst forming a catalyst systemunder polymerization conditions, wherein the polymerization catalystcomprises a particulate diluent selected from the group consisting ofsilica, silica-alumina, silica-titania, magnesium dichloride, magnesiumoxide, poly(phenylene)sulfide, polyethylene, and polypropylene and aproduct precipitated in the presence of the particulate diluent, theproduct being formed by adding under precipitation conditions aprecipitating agent to a mixture of a component solution and theparticulate diluent,wherein the component solution is formed by thecombination of: (1) a metal halide compound selected from the groupconsisting of metal dihalide compounds and metal hydroxyhalide compoundsand the metal of the metal halide compound is selected from the groupconsisting of Group IIA metals and Group IIB metals of the PeriodicTable, and (2) a transition metal compound in which the transition metalis selected from the group consisting of Group IVB and Group VBtransition metals of the Periodic Table and the transition metal isbonded to at least one atom selected from the group consisting ofoxygen, nitrogen and sulfur, and said oxygen, nitrogen and sulfur atomsare in turn bonded to a carbon atom of a carbon containing radical, in asuitable solvent; wherein the precipitating agent is selected from thegroup consisting of organometallic compounds wherein the metal isselected from the group consisting of Group I, Group II, and Group IIImetals of the Periodic Table, metal halides and oxygen containinghalides of elements selected from the group consisting of Group IIIA,Group IVA, Group IVB, Group VA, and Group VB of the Periodic Table,hydrogen, halides, and organic acid halides selected from the groupconsisting of compounds having the formula ##STR3## wherein R" is analkyl, aryl, or cycloalkyl group or combinations thereof containing from1 to about 12 carbon atoms and X is a halide; said polymerizationcatalyst further having been activated by treatment with a halogenatedmetal compound represented by the formula M'X_(c) (OR)_(d-c) in which M'is selected from the group consisting of zirconium, titanium, vanadium,silicon and tin, X stands for bromine, chlorine, iodine or mixturesthereof, R is alkyl, cycoalkyl, aryl or mixtures thereof, d is thevalence of M', and c is less than or equal to d and is an integer of 1to
 4. 10. A process as in claim 9 wherein the at least one alpha-olefincomprises a mono-1-olefin
 11. A process as in claim 9 wherein the atleast one alpha-olefin comprises ethylene.
 12. A process as in claim 9wherein the catalyst system further comprises an amount of prepolymerdeposited on the polymerization catalyst.
 13. A process as in claim 12wherein the particulate diluent comprises polyethylene fibrils andwherein the prepolymer comprises polyethylene.
 14. A process as in claim9 wherein the particulate diluent comprises silica, wherein the metalhalide compound comprises magnesium dichloride, wherein the transitionmetal compound comprises titanium tetraalkoxide, the precipitating agentis selected from the group consisting of ethylaluminum sesquichlorideand ethylaluminum dichloride, and the halogenated metal compoundcomprises titanium tetrachloride.
 15. A process as in claim 14 whereinthe cocatalyst comprises at least one organoaluminum compoundrepresented by the formula AlR"'_(e) Y_(3-e) wherein R"' represents ahydrocarbyl radical containing from 1 to about 20 carbon atoms, Yrepresents a monovalent radical selected from the group consisting ofhydrogen and halogen and e is an integer of 1 to 3, the combinationforming a catalyst system.
 16. A process as in claim 15 wherein thecatalyst system is contacted with ethylene in a presence of a liquidhydrocarbon diluent under conditions of temperature and pressure suchthat the diluent is in the liquid phase and the resulting polymer issubstantially insoluble in said diluent.